Fiber optic drop cables and preconnectorized assemblies having toning portions

ABSTRACT

A preconnectorized outdoor cable streamlines the deployment of optical waveguides into the last mile of an optical network. The preconnectorized outdoor cable includes a cable and at least one plug connector. The plug connector is attached to a first end of the cable, thereby connectorizing at least one optical waveguide. The cable has at least one optical waveguide, at least one tensile element, and a cable jacket. Various cable designs such as figure-eight or flat cables may be used with the plug connector. In preferred embodiments, the plug connector includes a crimp assembly having a crimp housing and a crimp band. The crimp housing has two half-shells being held together by the crimp band for securing the at least one tensile element. When fully assembled, the crimp housing fits into a shroud of the preconnectorized cable. The shroud aides in mating the preconnectorized cable with a complimentary receptacle.

RELATED APPLICATIONS

The present application is a Continuation-in-Part of co-pending U.S.patent application Ser. Nos. 10/765,434, 10/765,262, and 10/765,428 allfiled on Jan. 27, 2004, the disclosures of which are incorporated hereinby reference, which are Continuation-in-Parts of U.S. Ser. No.10/294,136 filed on Nov. 14, 2002 now U.S. Pat. No. 6,714,710, which isa Continuation of U.S. Ser. No. 09/645,916 filed on Aug. 25, 2000 nowU.S. Pat. No. 6,542,674. U.S. patent application Ser. Nos. 10/765,434,10/765,262, and 10/765,428 are also Continuation-in-Parts of co-pendingU.S. Ser. No. 10/659,666 filed on Sep. 10, 2003, which is a Divisionalof U.S. Ser. No. 09/967,259 filed on Sep. 28, 2001 now U.S. Pat. No.6,648,520 and Continuation-in-Parts of U.S. Ser. No. 10/383,468 filed onMar. 7, 2003 now U.S. Pat. No. 6,785,450, which is a Continuation ofU.S. Ser. No. 09/579,555 filed on May 26, 2000 now U.S. Pat. No.6,546,175.

FIELD OF THE INVENTION

The present invention relates generally to optical cables and networks.More specifically, the invention relates to preconnectorized fiber opticdrop cables and assemblies useful for optical networks that bring fiberto the ‘x’ location (FTTx) and the like.

BACKGROUND OF THE INVENTION

Communication networks are used to transport a variety of signals suchas voice, video, data transmission, and the like. Traditionalcommunication networks use copper wires in cables for transportinginformation and data. However, copper cables have drawbacks because theyare large, heavy, and can only transmit a relatively limited amount ofdata. On the other hand, an optical waveguide is capable of transmittingan extremely large amount of bandwidth compared with a copper conductor.Moreover, an optical waveguide cable is much lighter and smallercompared with a copper cable having the same bandwidth capacity.Consequently, optical waveguide cables replaced most of the coppercables in long-haul communication network links, thereby providinggreater bandwidth capacity for long-haul links. However, many of theselong-haul links have bandwidth capacity that is not being used. This isdue in part to communication networks that use copper cables fordistribution and/or drop links on the subscriber side of the centraloffice. In other words, subscribers have a limited amount of availablebandwidth due to the constraints of copper cables in the communicationnetwork. Stated another way, the copper cables are a bottleneck thatinhibit the subscriber from utilizing the relatively high-bandwidthcapacity of the long-hauls links.

As optical waveguides are deployed deeper into communication networks,subscribers will have access to increased bandwidth. But there arecertain obstacles that make it challenging and/or expensive to routeoptical waveguides/optical cables deeper into the communication network,i.e., closer to the subscriber. For instance, making a suitable opticalconnection between optical waveguides is much more difficult than makingan electrical connection between copper wires. This is because opticalconnections require special tools and equipment, highly trainedcraftsman, along with precision components. Additionally, as thecommunication network pushes toward subscribers, the communicationnetwork requires more connections, which compounds the difficulties ofproviding optical waveguides to the premises of the subscriber. Hence,the routing of optical waveguides to the proverbial last mile of thenetwork has yet to enjoy commercial success.

One common way to connect optical waveguides is by using opticalconnectors. Optical connectors generally hold the mating opticalwaveguides in respective ferrules of the mating connectors. The ferrulesand optical waveguides therein require polishing of the end face forproper operation. Polishing a ferrule is a relatively complex processthat generally requires several steps along with inspection and testingusing precision equipment to verify an acceptable insertion loss. Inother words, installing connectors is best performed in a factorysetting under ideal working conditions.

Another common way to make an optical connection is by fusion splicing.Fusion splicing requires that the ends of the optical fibers beprecisely aligned so that the transfer the optical signal between theends of the optical waveguides has a relatively low-loss. But likeconnectors, fusion splicing requires highly trained craftsman andspecial equipment to make and test the optical connection, therebymaking it a relatively expensive and inefficient proposition for fieldconnectorization. Thus, there is need for an efficient and relativelylow-cost method of reliably making optical connections in the fieldwithout using specialized equipment and highly skilled labor.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 schematically depicts a portion of an optical communicationnetwork for providing fiber to the subscriber at location ‘x’ (FTTx).

FIG. 2 schematically illustrates the drop link portion of the opticalnetwork of FIG. 1 having a preconnectorized fiber optic drop cableaccording to the present invention.

FIG. 3 a-c shows a portion of the preconnectorized fiber drop cablebeing plugged into a receptacle according to the present invention.

FIG. 4 is an assembled perspective view of the preconnectorized fiberoptic drop cable having an optional toning portion according to thepresent invention.

FIG. 5 is an exploded view of the preconnectorized fiber optic dropcable.

FIGS. 5 a and 5 b respectively are a perspective view and a sectionalview of the shroud of FIG. 4.

FIG. 6 is a cross-sectional view of the cable taken along line 6-6 asshown in FIG. 4.

FIG. 6 a is a perspective view of the cable of FIG. 5 prepared forconnectorization.

FIG. 6 b is a perspective view of one half-shell of the crimp housing ofFIG. 5.

FIG. 6 c shows a portion of the connector assembly of FIG. 4 attached tothe cable and positioned within the half-shell of FIG. 6 b.

FIG. 6 d shows the partially assembly crimp assembly being attached tothe cable.

FIG. 7 is a cross-sectional view of the preconnectorized fiber opticdrop cable taken along line 7-7 as shown in FIG. 4.

FIG. 8 is a cross-sectional view of another fiber optic drop cableaccording to the present invention.

FIG. 9 depicts a portion of a crimp housing that is suitable for thefiber optic drop cable shown in FIG. 8.

FIG. 10 is a perspective view of a cable similar to FIG. 8 prepared forconnectorization.

FIG. 11 shows a partially assembly crimp assembly being attached to acable similar to the cable of FIG. 6 having more than one opticalwaveguide.

FIG. 12 is a perspective view of one half-shell of the crimp housing ofFIG. 11.

FIGS. 13 a-13 m depict cross-sectional views of other exemplary fiberoptic cables that are suitable for preconnectorization according to thepresent invention.

FIGS. 14 a and 14 b respectively show the cable of FIG. 13 e preparedfor connectorization and the same cable during the process of attachingthe crimp assembly.

FIGS. 15 a and 15 b depict cross-sectional views of cables having atleast one electrical conductor for transmitting electrical power.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described more fully hereinafter withreference to the accompanying drawings showing preferred embodiments ofthe invention. The invention may, however, be embodied in many differentforms and should not be construed as limited to the embodiments setforth herein; rather, these embodiments are provided so that thedisclosure will fully convey the scope of the invention to those skilledin the art. The drawing are not necessarily drawn to scale but areconfigured to clearly illustrate the invention.

FIG. 1 schematically depicts a portion of an optical waveguide network 1in an exemplary fiber to the location ‘x’ (FTTx). ‘x’ in the acronymrepresents the end location of the optical waveguide, for instance, FTTCis fiber to the curb. In this case, network 1 is a fiber to the premises(FTTP) application. FTTP architectures advantageously route at least oneoptical waveguide to the premises, thereby providing a high bandwidthconnection to the subscriber. Applications to locations other than tothe curb or premises are also possible. Downstream from a central officeCO, network 1 includes a feeder link 2, a first 1:N splitter 3, adistribution link 4, a second 1:M splitter 5, and at least one drop link6. In the present invention, drop link 6 comprises a preconnectorizedfiber optic drop cable 10 (hereinafter preconnectorized cable) suitablefor outdoor environments. Preconnectorized cable 10 effectively andeconomically streamlines the deployment and installation of opticalwaveguides into the last mile of the fiber optic network such as to thepremises. Although, network 1 shows a simple configuration of one typeof FTTx architecture, other networks can employ the present invention.Other networks may include other suitable components such asdistribution closures, amplifiers, couplers, transducers, or the like.Likewise, other networks besides FTTX architectures can also benefitfrom the concepts of the present invention.

For explanatory purposes, FIG. 2 schematically illustrates twopreconnectorized cables 10 and 10′ being routed to a premises 20 usingdifferent exemplary techniques. Specifically, FIG. 2 shows firstpreconnectorized cable 10 being routed to premises 20 in an aerialapplication and second preconnectorized cable 10′ being routed topremise 20 in a buried application. In the aerial application, a firstend 10 a of preconnectorized cable 10 is attached at a first interfacedevice 12 located on pole 11 and a second end 10 b of preconnectorizedcable 10 is attached at interface device 14 located at the subscriberpremises 20. In buried applications, the first and second ends ofpreconnectorized cable 10′ are respectively connected to interfacedevice 16 located inside pedestal 18 and interface device 14. Theinterface devices include at least one receptacle 30 for making theoptical connection with an end of preconnectorized cable 10.

FIGS. 3 a-c show the various stages during the mating of an end ofpreconnectorized cable 10 with receptacle 30. Specifically, FIG. 3 ashows receptacle 30 detached from preconnectorized cable 10. Moreover,preconnectorized cable 10 and receptacle 30 are depicted with theirrespective protective caps on. Protective cap 68 is used for shielding aconnector assembly 52, and in particular, the end face of a connectorferrule 52 b from the elements and/or damage. Specifically, installedprotective cap 68 isolates connector ferrule 52 b from the elements andprevents it from being damaged during transportation and handling. FIG.3 b shows protective cap 68 removed from the end of preconnectorizedcable 10. Likewise, the respective cap of receptacle 30 is also removed.Preconnectorized cable 10 is positioned to engage the complimentaryportions of receptacle 30. Specifically, an alignment indicia 60 c ofpreconnectorized cable 10 is positioned to its complementary indicia 30c of receptacle 30. FIG. 3 c shows a mated connection between thepreconnectorized cable 10 and receptacle 30, thereby making an opticalconnection therebetween. As readily apparent, no special equipment,training, or skill is required to make the optical connection. Thus, thelabor cost of deploying the optical network to the premises is costeffective and efficient. In this case, the mating between the plugconnector and the receptacle is secured using a threaded engagement, butother suitable means of securing the optical connection are possible.For instance, the securing means may use a quarter-turn lock, a quickrelease, a push-pull latch, or a bayonet configuration.

FIG. 4 depicts a perspective view of an assembled preconnectorized cable10 having an optional toning portion. Preconnectorized cable 10 includesa fiber optic cable 40 (hereinafter cable 40) and an optical plugconnector 50 mounted upon one end of cable 40. In this embodiment, cable40 is a flat dielectric cable having a toning portion that is configuredas a toning lobe 41 connected by a web portion. As shown, a portion oftoning lobe 41 is separated and coiled before optical plug connector 50,thereby keeping it out of way. Optical plug connector 50 uses aconnector assembly 52 of the SC type, but other types of connectorassemblies such as LC, FC, ST, MT, and MT-RJ are contemplated by thepresent invention by using a suitable crimp housing.

As best shown in FIG. 6, cable 40 has an optical component 42, at leastone strength component 44, a jacket 48, and toning lobe 41. In thiscable, strength component 44 has two glass-reinforced plastic (grp)strength components and optical component 42 has an optical waveguide 46disposed within a buffer tube 43. Cable 40 also includes strengthmembers 45 to provide additional tensile strength. As used herein, theterm “strength component” means the strength element has anti-buckingstrength, while the term “strength member” means a strength elementlacks anti-buckling strength. Furthermore, the term “tensile element”means either a strength component or a strength member. Strength members45 allow cable 40 to have a smaller cross-sectional footprint becausethey allow strength components 44 to have smaller diameters since theywill not provide all of the tensile strength to cable 40. In otherwords, the tensile load is carried by both strength components 44 andstrength members 45. Moreover, using strength members 45 maintains arelatively flexible outdoor cable that is easier to handle. Of course,other cables may be used with the concepts of the present invention andother exemplary cables will be discussed herein. Moreover, suitableconnector assemblies may be used with suitable cables according to theconcepts of the present invention, thereby resulting in numerouscable/connector combinations.

Cable 40 is an all-dielectric design except for the inclusion of aconductive wire 41 a of toning lobe 41. Specifically, conductive wire 41a is by way of example a copper 24 gauge wire having a jacket portion 48a therearound. Jacket portion 48 a is connected to jacket 48 by the web(not numbered) so that toning lobe 41 can easily separated from theremainder of the cable by tearing the web, thereby making itcraft-friendly. As depicted, the web also includes a preferential tearportion (not numbered) for controlling the location of the tear in theweb. Jacket 48 and jacket portion 48 a are typically co-extruded usingthe same extrusion tooling. Conductive wire 41 a is useful for locatingthe otherwise dielectric cable if it is buried. In other words, thecraftsman can run a toning signal through conductive wire 41 a to locatethe cable if it is buried so it can be located and/or marked to preventinadvertent damage.

FIG. 5 depicts an exploded view of preconnectorized cable 10 showingcable 40′ as disclosed in U.S. Pat. No. 6,542,674 and plug connector 50.Cable 40′ is similar to cable 40, but it does not include the toninglobe and both cables may use the same plug connector design. In thisembodiment, plug connector 50 includes an industry standard SC typeconnector assembly 52 having a connector body 52 a, a ferrule 52 b in aferrule holder (not numbered), a spring 52 c, and a spring push 52 d.Plug connector 50 also includes a crimp assembly (not numbered) thatincludes a crimp housing having at least one half-shell 55 a and a crimpband 54, a shroud 60 having an O-ring 59, a coupling nut 64, a cableboot 66, a heat shrink tube 67, and a protective cap 68 secured to boot66 by a wire assembly 69.

Generally speaking, most of the components of plug connector 50 areformed from a suitable polymer. Preferably, the polymer is a UVstabilized polymer such as ULTEM 2210 available from GE Plastics;however, other suitable materials are possible. For instance, stainlesssteel or any other suitable metal may be used for various components.Additionally, FIG. 7 shows a cross-sectional view of preconnectorizedcable 10 taken along line 7-7 of FIG. 4.

As best shown in FIG. 6 d, the crimp assembly includes crimp housing 55and crimp band 54. Crimp housing 55 has two half-shells 55 a that areheld together by crimp band 54 when the preconnectorized cable isassembled. Although, the term half-shell is used, it is to be understoodthat it means suitable shells and includes shells that are greater thanor less than half of the crimp housing. Crimp band 54 is preferably madefrom brass, but other suitable crimpable materials may be used. Crimphousing 55 is configured for securing connector assembly 52 as well asproviding strain relief to cable 40′. This advantageously results in arelatively compact connector arrangement using fewer components.Moreover, the crimp assembly allows preconnectorized cable 10 to beassembled quickly and easily. Of couse, other embodiments are possibleaccording to the present invention. For instance, connector body 52 amay be integrally molded into crimp housing 55 in a ST typeconfiguration so that a twisting motion of the crimp housing secures theST-type connector with a complementary mating receptacle.

FIGS. 6 a-6 d depict several steps during the process of attaching thecrimp assembly to cable 40′. FIG. 6 a shows cable 40′ having strengthmembers 45 (not visible) cut flush with the stripped back jacket 48,thereby exposing the two grp strength components 44 and opticalcomponent 42 from the end of cable 40′. FIG. 6 b shows the inner surfaceof one half-shell 55 a. In this case, only one half-shell 55 a isillustrated since two symmetrical half-shells are used for both halvesof crimp housing 55. In other embodiments there may be a firsthalf-shell and a second half-shell, which are different. For instance,one half-shell may have two alignment pins, rather than each half-shellhaving a single alignment pin.

As shown in FIG. 6 b, half-shell 55 a includes a first end 55 b forsecuring connector assembly 52 and a second end 55 c that providesstrain relief. A longitudinal axis A-A is formed between first end 55 band second end 55 c near the center of crimp housing 55, through whichhalf of a longitudinal passage is formed. When assembled, optical fiber46 passes through the longitudinal passage and is held in a bore offerrule 52 b. Additionally, half-shell 55 a includes a cable clampingportion 56 and a connector assembly clamping portion 57.

Cable clamping portion 56 has two outboard half-pipe passageways 56 aand a central half-pipe passageway 56 b that is generally disposed alonglongitudinal axis A-A. Half-pipe passageways 56 a and 56 b preferablyinclude at least one rib 56 c for securely clamping optical component 42and strength components 44 after crimp band 54 is crimped, therebycompleting the crimp assembly. Moreover, half-pipe passageways 56 a and56 b are sized for the components of cable 40′, but the passageways canbe sized for different cable configurations.

Likewise, half-shell 55 a has a connector assembly clamping portion 57that is sized for attaching connector assembly 52. Specifically,connector assembly clamping portion 57 has a half-pipe passageway 57 athat opens into and connects central half-pipe passageway 56 b and apartially rectangular passageway 57 b. Half-pipe passageway 57 a issized for securing spring push 52 d and may include one or more ribs forthat purpose. Rectangular passageway 57 b holds a portion of connectorbody 52 a therein and inhibits the rotation between connector assembly52 and the crimp assembly. FIG. 6 c depicts prepared cable 40′ of FIG. 6a having connector assembly 52 attached and positioned in a firsthalf-shell 55 a. The alignment of the two half shells is accomplished byinserting pins 57 c into complementary bores 57 d of the twohalf-shells. FIG. 6 d shows both half-shells 55 a of crimp housing 55disposed about cable 40′ before crimp band 54 is installed thereover.Additionally, half-shells may include one or more bores 56 d that leadto one of half-pipe passageways 56 a or 56 b. Bores 56 d allow forinserting an adhesive or epoxy into the crimp housing 55, therebyproviding a secure connection for strain relief.

As shown in FIG. 7, when fully assembled the crimp assembly fits intoshroud 60. Additionally, crimp housing 55 is keyed to direct theinsertion of the crimp assembly into shroud 60. In this case,half-shells 55 a include planar surfaces 57 e (FIG. 6 d) on oppositessides of crimp housing 55 to inhibit relative rotation between crimphousing 55 and shroud 60. In other embodiments, the crimp assembly maybe keyed to the shroud using other configurations such as acomplementary protrusion/groove or the like.

Shroud 60 has a generally cylindrical shape with a first end 60 a and asecond end 60 b. Shroud generally protects connector assembly 52 and inpreferred embodiments also keys plug connector 50 with the respectivemating receptacle 30. Moreover, shroud 60 includes a through passagewaybetween first and second ends 60 a and 60 b. As discussed, thepassageway of shroud 60 is keyed so that crimp housing 54 is inhibitedfrom rotating when plug connector 50 is assembled. Additionally, thepassageway has an internal shoulder (not numbered) that inhibits thecrimp assembly from being inserted beyond a predetermined position.

As best shown in FIGS. 5 a and 5 b, first end 60 a of shroud 60 includesat least one opening (not numbered) defined by shroud 60. The at leastone opening extends from a medial portion of shroud 60 to first end 60a. In this case, shroud 60 includes a pair of openings on, oppositesides of first end 60 a, thereby defining alignment portions or fingers61 a,61 b. In addition to aligning shroud 60 with receptacle duringmating, alignment fingers 61 a,61 b may extend slightly beyond connectorassembly 52, thereby protecting the same. As shown in FIG. 5 b,alignment fingers 61 a,61 b have different shapes so plug connector 50and receptacle 30 only mate in one orientation. In preferredembodiments, this orientation is marked on shroud 60 using alignmentindicia 60 c so that the craftsman can quickly and easily matepreconnectorized cable 10 with receptacle 30. In this case, alignmentindicia 60 c is an arrow molded into the top alignment finger of shroud60, however, other suitable indicia may be used. As shown, the arrow isaligned with complimentary alignment indicia 30 c disposed on receptacle30, thereby allowing the craftsman to align indicia 60 c,30 c so thatalignment fingers 61 a,61 b can be seated into receptacle 30.Thereafter, the craftsman engages the external threads of coupling nut64 with the complimentary internal threads of receptacle 30 to make theoptical connection as shown in FIG. 3 c.

A medial portion of shroud 60 has a groove 62 for seating an O-ring 59.O-ring 59 provides a weatherproof seal between plug connector 50 andreceptacle 30 or protective cap 68. The medial portion also includes ashoulder 60 d that provides a stop for coupling nut 64. Coupling nut 64has a passageway sized so that it fits over the second end 60 b ofshroud 60 and easily rotates about the medial portion of shroud 60. Inother words, coupling nut 64 cannot move beyond shoulder 60 d, butcoupling nut 64 is able to rotate with respect to shroud 60. Second end60 b of shroud 60 includes a stepped down portion having a relativelywide groove (not numbered). This stepped down portion and groove areused for securing heat shrink tubing 67. Heat shrink tubing 67 is usedfor weatherproofing the preconnectorized cable. Specifically, thestepped down portion and groove allow for the attachment of heat shrinktubing 67 to the second end 60 b of shroud 60. The other end of heatshrink tubing 67 is attached to cable jacket 48, thereby inhibitingwater from entering plug connector 50.

After the heat shrink tubing 67 is attached, boot 66 is slid over heatshrink tubing 67 and a portion of shroud 60. Boot 66 is preferablyformed from a flexible material such as KRAYTON. Heat shrink tubing 67and boot 66 generally inhibit kinking and provide bending strain reliefto the cable near plug connector 50. Boot 66 has a longitudinalpassageway (not visible) with a stepped profile therethrough. The firstend of the boot passageway is sized to fit over the second end of shroud60 and heat shrink tubing 67. The first end of the boot passageway has astepped down portion sized for cable 40′ and the heat shrink tubing 67and acts as stop for indicating that the boot is fully seated. Afterboot 66 is seated, coupling nut 64 is slid up to shoulder 60 c so thatwire assembly 69 can be secured to boot 66. Specifically, a first end ofwire assembly 69 is positioned about groove 66 a on boot 66 and wire 69a is secured thereto using a first wire crimp (not numbered). Thus,coupling nut 64 is captured between shoulder 60 c of shroud 60 and wireassembly 69 on boot 66. This advantageously keeps coupling nut 64 inplace by preventing it from sliding past wire assembly 69 down ontocable 40′.

A second end of wire assembly 69 is secured to protective cap 68 using asecond wire crimp (not numbered). Consequently, protective cap 68 isprevented from being lost or separated from preconnectorized cable 10.In this embodiment, wire assembly 69 is attached to protective cap 68 atan eyelet 68 a. Eyelet 68 a is also useful for attaching a fish-tape sothat preconnectorized cable 10 can be pulled through a duct. Protectivecap 68 has internal threads for engaging the external threads ofcoupling nut 64. Moreover, O-ring 59 provides a weatherproof sealbetween plug connector 50 and protective cap 68 when installed. Whenthreadly engaged, protective cap 68 and coupling nut 64 may rotate withrespect to the remainder of preconectorized cable 10, thus inhibitingtorsional forces during pulling.

Preconnectorized cable 10 may have any suitable length desired, however,preconnectorized cable 10 can have standardized lengths. Moreover,preconnectorized cable 10 may include a length marking indicia foridentifying its length. For instance, the length marking indicia may bea marking located on the cable such as a colored stripe or denoted in aprint statement. Likewise, the length marking indicia may be a markinglocated on plug connector 50. In one embodiment, length marking indiciamay be denoted by a marking on coupling nut 64 or protective cap 68 suchas a colored stripe. In any event, the length marking indicia should beeasily visible so the craftsperson may identify the preconnectorizedcable length. For instance, a red marking indicia on coupling nut 64denotes a length of about 50 feet while an orange marking indiciadenotes a length of about 100 feet.

The described explanatory embodiment provides an optical connection thatcan be made in the field without any special tools, equipment, ortraining. Additionally, the optical connection is easily connected ordisconnected by merely mating or unmating the ends of preconnectorizedcable 10 with the respective receptacle by threadly engaging ordisengageing coupling nut 64. Thus, the preconnectorized cables of thepresent invention allow deployment of optical waveguides to the location‘x’ in an easy and economical manner, thereby providing the end userwith increased bandwidth. Furthermore, the concepts of the presentinvention can be practiced with other fiber optic cables, connectorsand/or other preconnectorized cable configurations.

FIG. 8 is a cross-sectional view of another fiber optic cable 80suitable with the concepts of the present invention. Cable 80 is anexplanatory figure eight cable design having a messenger section 82 anda carrier section 84 connected by a web 83. Messenger section 82includes at least one strength component 86 having anti-bucklingstrength and tensile strength for carrying a load. Strength component 86can be formed from any suitable material such as dielectrics orconductors, moreover, a plurality of strength components 86 may bestranded together as shown. In this cable, carrier section 84 includesan optical component that includes at least one optical waveguide 81 anda buffer tube 85, and generally excludes strength components andstrength members. However, preconnectorized cables of the presentinvention may use figure eight cables having strength components and/orstrength members in the carrier section. The messenger and carriersections 82,84 include a common cable jacket 89. Common jacket 89includes a messenger jacket 89 a and a carrier jacket 89. Additionally,carrier section 84 also includes at least one ripcord 87 for accessingoptical waveguide 81.

A preconnectorized cable employing cable 80 uses a design similar topreconnectorized cable 10, but some of the components are different dueto the figure eight design of cable 80. Specifically, cable 80 requiresa different crimp housing than used for cables 40 or 40′. FIG. 9illustrates a half-shell 95 a that is suitable for using as a portion ofthe crimp housing for preconnectorizing cable 80. Generally speaking,half-shell 95 a has the same outer dimensions as half-shell 55 a so bymerely substituting crimp housings different cable designs may be usedwith plug connector 50. Like crimp housing 55, crimp housing 95 uses twosymmetrical half-shells 95 a, thus only one half-shell requiresillustration. In this case, passageway 96 b is not symmetric aboutlongitudinal axis A-A. Instead, passageway 96 a has a non-symmetricalcurvilinear path between first end 95 b and second end 95 c aboutlongitudinal axis A-A. Furthermore, embodiments of the present inventionmay use crimp housings having other configurations for different cables.

FIG. 10 illustrates fiber optic cable 80 having an end prepared forconnectorization. Specifically, a portion of jacket 89 is stripped back,thereby exposing strength component 86, buffer tube 85, and opticalwaveguide 81. Next, connector assembly 52 is attached to opticalwaveguide 81 forming a subassembly. Thereafter, the subassembly isplaced into the proper portions of half-shell 95 a. Like half-shell 55,half-shell 95 a includes a cable clamping portion 96 and a connectorassembly clamping portion 97. Crimp housing 95 (not shown) is thenformed about a portion of the subassembly by placing a second half-shell95 a onto the first half-shell 95 a.

Specifically, half-shell 95 a includes a first end 95 b for securingconnector assembly 52 and a second end 95 c that provides strain relief.A longitudinal axis A-A is formed between first end 95 b and second end95 c near the center of the crimp housing. A through longitudinalpassage is formed between first ends 95 b and second ends 95 c of crimphousing 95; however, the passageway is not generally symmetrical aboutlongitudinal axis A-A. When assembled, optical fiber 81 passes throughthe longitudinal passage and is held in a bore of ferrule 52 b. Cableclamping portion 96 has a single half-pipe passageway 96 a and acurvilinear half-pipe passageway 96 b. Half-pipe passageways 96 a and 96b preferably include a plurality of ribs 96 c for securely clampingbuffer tube 85 and strength component 86 after crimp band 54 is crimpedabout crimp housing 95, thereby completing the crimp assembly.

Likewise, half-shell 95 a has a connector assembly clamping portion 97that is sized for attaching connector assembly 52. Specifically,connector assembly clamping portion 97 has a half-pipe passageway 97 athat opens into and connects curvilinear half-pipe passageway 96 b and apartially rectangular passageway 97 b. Half-pipe passageway 97 a issized for securing spring push 52 d and may include one or more ribs forthat purpose. Rectangular passageway 97 b holds a portion of connectorbody 52 a therein and inhibits the rotation between connector assembly52 and the crimp assembly. The alignment of the two half shells 95 a isaccomplished by inserting pins 97 c into complementary bores 97 d of thetwo half-shells. Additionally, half-shells 95 a may include one or morebores 96 d that lead to one of half-pipe passageways for inserting anadhesive or epoxy into the crimp housing.

Preconnectorized cables of the present invention can also terminate morethan one optical waveguide. A plurality of optical waveguide can bearranged loosely, disposed in a ribbon, or bundlized. For instance, FIG.11 depicts a cable 40″ having more than one optical waveguide therein.As shown, a crimp housing 114 is suitable for securing more than oneconnector assembly 112. As depicted in FIG. 12, half-shell 114 a has twoconnector assembly clamping portions 117. Moreover, the half-shells ofcrimp housing 114 are non-symmetrical since half-shell 114 a has a bore117 a and the complementary half-shell (not shown) would have analignment pin. Furthermore, crimp housings of the present invention mayhold one or more multi-fiber ferrules.

Likewise, a variety of different cables can be used with the presentinvention. For instance, FIGS. 13 a-13 n depict suitable cables 130a-130 n having at least one strength component or strength member 134,at least one optical waveguide 136, and a cable jacket 138. Cables 130a-130 n will be briefly described. Additionally, all of the disclosuresof the below mentioned patents and patent applications are incorporatedherein by reference.

FIG. 13 a shows a cable 130 a that is similar to cable 40 that has atoning portion 131 a. However, among other features, cable 130 a doesnot include strength members 45 that lack anti-buckling strength.However, there are several possible variations of this configurationsuch as a tubeless design with or without the inclusion of strengthmembers. Additionally, optical waveguide 136 is a portion of an opticalfiber ribbon, but other suitable configurations such as tight-bufferedoptical fiber may be used. FIG. 13 b is another similar cable designhaving a toning portion 131 b, but jacket 138 has a medial lobesurrounding a tube that houses optical waveguides 136, which aredisposed in a bundle. Other suitable cable designs may also include atoning portion that can be configured as a separate lobe connected by aweb or integrated into a cable body. FIG. 13 c shows a round cable 130 cas disclosed in U.S. patent application Ser. No. 09/822,528 and Ser. No.09/822,529 both filed on Mar. 30, 2001. Additionally, optical waveguide136 has a buffer layer (not numbered) for protection. FIG. 13 d depictsa variation of the strength component 134 of cable 130 c for a flat dropcable.

FIG. 13 e is a round cable 130 e having a plurality of strength members134 such as aramid fibers or fiberglass rovings. As shown in FIGS. 14 aand 14 b, strength members 134 of cable 130 e are secured to plugconnector 50 by being captured between an outer barrel 55 o of crimphousing 55 and the inner diameter of crimp band 54 during crimping.Specifically, FIG. 14 a shows a cable 130 e prepared forconnectorization and FIG. 14 b shows strength members 134 beingpositioned about outer barrel 55 o before installing crimp band 54. Ofcourse other techniques are possible for securing strength members 134,but using this technique allows one configuration of crimp housing 55 toaccommodate several different types of cables. Cable 130 f is avariation of cable 130 e having a generally flat shape. Thus, part ofthe passageway through the boot of the plug connector 50 should conformwith the cable profile, thereby allowing the boot to be slid onto thecable.

FIG. 13 g depicts yet another cable 130 g as disclosed in U.S. Pat. No.6,256,438. In this cable, strength component 134 is an armor tube thathouses optical waveguides 136 and water-swellable element 137 such as awater-swellable yarn. FIG. 13 h shows another figure-eight cable asdisclosed in U.S. Pat. No. 6,356,690. Cable 130 h includes strengthcomponents 134 in both the messenger and carrier sections. The primarystrength is provided by the strength component of the messenger section,but the strength components of the carrier section generally inhibitshrinkback of carrier jacket 138 b when the two sections are separated.Moreover, strength components 134 in the carrier section are generallylocated along plane A-A. FIG. 13 i shows cable 130 i, which is anothervariation of a figure-eight cable. In this cable, a slotted core 135 isused for holding optical ribbons in a plurality of stacks, but otherconfigurations are possible. Slotted core 135 is wrapped with awater-swellable element 137 such as a tape, which is secured with one ormore binder threads before jacket is extruded thereover.

FIG. 13 j shows cable 130 j as disclosed in U.S. Pat. No. 6,621,964.Cable 130 j includes two non-stranded strength components 134 withoptical waveguides 136 and water-swellable components 137 surrounded byjacket 138. FIG. 13 k illustrates cable 130 k as also disclosed in U.S.Pat. No. 6,621,964. Cable 130 k has inner and outer components that maybe strength components 134 that house at least one optical waveguide 136generally surrounded by a jacket 138. FIG. 131 shows cable 1301 asdisclosed in U.S. Pat. No. 6,618,526. Cable 1301 has two strengthcomponents 134 that share two or more interfaces with a retention areatherebetween that houses optical waveguide 136.

FIGS. 13 m and 13 n show cables 130 m and 130 n having a dry insert 131as disclosed in U.S. patent application Ser. Nos. 10/326,022 filed onDec. 19, 2002 and 10/661,204 filed on Sep. 12, 2003. Additionally,cables 13 m and 13 n are tubeless cable designs. In other words, thecraftsman does not have to open a buffer tube to access the opticalwaveguides. Cable 130 m includes optical waveguides 136 generallydisposed within dry insert 131, and one or more binder threads thatsecure dry insert 131, two strength components 134, and jacket 138.Cable 130 m also has a pair of ripcords 133 disposed about 180 degreesapart. Cable jacket 138 includes a plurality of ears 139 that aregenerally disposed to indicate the location of ripcords 133 to thecraftsman. FIG. 13 n shows a figure-eight cable 130 n that is similar tocable 130 m, except it includes a messenger section connected by a web.Likewise, other cable design may use a dry insert and/or have a tubelessconfiguration. The illustrated cables may also include other components,configurations, and/or different materials. For instance cables caninclude components such as armor layers, ripcords, water-swellableyarns, tapes, or powders. Optical waveguide can also be loose,ribbonized, or have buffer layers.

Additionally, the preconnectorized cables according to the presentinvention may also have electrical power components that are connectedand disconnected through the plug connector. FIGS. 15 a and 15 b depictcables 150 a and 150 b that are suitable for carrying electrical power.Cable 150 a has insulated electrical wires 151 located in outboard lobesof jacket 138. Cable 150 b also includes electrical wires 151 on theoutboard portions surrounded by jacket 138 having preferential tearportions 138 c. Electrical wires 151 are also multi-functional sincethey act as strength components in these cable designs. Electrical wires151 may be any suitable electrical conductor such as copper wires orcopper clad steel. In the preconnectorized cable, electrical wires 151would be electrically connected with respective conductive terminals ofthe plug connector that are suitable for mating with complementaryelectrical terminals in the receptacle. For instance, electrical wires151 may be in electrical communication with a portion of a conductiveterminal. For instance, the electrical terminal may run from electricalwire 151 in the half shell to the connector assembly 52 or adjacent tofingers 61 a,61 b; however, other suitable configurations are possible.

Many modifications and other embodiments of the present invention,within the scope of the appended claims, will become apparent to askilled artisan. Additionally, the present invention can include othersuitable configurations, hybrid designs, structures and/or equipment.Therefore, it is to be understood that the invention is not limited tothe specific embodiments disclosed herein and that modifications andother embodiments may be made within the scope of the appended claims.Although specific terms are employed herein, they are used in a genericand descriptive sense only and not for purposes of limitation. Theinvention has been described with reference to drop cables having FTTxapplications, but the inventive concepts of the present invention areapplicable to other suitable applications.

1. A preconnectorized outdoor cable comprising: a cable having at leasttwo strength components, an optical transmission component, a toningportion including a conductive wire and a cable jacket, wherein thecable jacket generally surrounds the at least two strength components,the optical transmission component, and the toning portion; and at leastone plug connector, the at least one plug connector being attached to anend of the cable, thereby connectorizing an optical waveguide, theoptical waveguide being a portion of the optical transmission component,the at least one plug connector having a shroud with a first end and asecond end, the shroud includes a plurality of fingers for mating with acomplementary receptacle, wherein at least two of the fingers havedifferent profiles for keying the plug connector with the complementaryreceptacle.
 2. The preconnectorized outdoor cable of claim 1, the atleast one plug connector further comprises a crimp assembly and aconnector assembly, wherein the crimp assembly includes a crimp housingand a crimp band and the connector assembly includes a connector housingand a ferrule.
 3. The preconnectorized outdoor cable of claim 2, whereinthe crimp housing comprises two half-shells, the two half-shells havinga longitudinal passageway therethrough and at least one cable clampingportion, the at least one cable clamping portion securing at least onestrength component of the cable, and the two half-shells being heldtogether by the crimp band.
 4. The preconnectorized outdoor cable ofclaim 2, wherein the crimp housing comprises two half-shells, the twohalf-shells having a longitudinal passageway therethrough, at least onecable clamping portion, and a connector assembly clamping portion, theat least one cable clamping portion securing at least one strengthcomponent of the cable and the connector assembly clamping portionsecuring a portion of the connector assembly, the two half-shells beingheld together by the crimp band.
 5. The preconnectorized outdoor cableof claim 1, the cable further comprising at least one tensile strengthmember.
 6. The preconnectorized outdoor cable of claim 5, the at leastone tensile strength member including a water-swellable material.
 7. Thepreconnectorized outdoor cable of claim 5, the at least one tensilestrength member being a plurality fiberglass strands.
 8. Thepreconnectorized outdoor cable of claim 1, the two strength componentsbeing a dielectric material.
 9. The preconnectorized outdoor cable ofclaim 1, the toning portion being a toning lobe connected by a web,wherein the web can be torn to separate the toning lobe.
 10. Thepreconnectorized outdoor cable of claim 1, the at least two strengthcomponents having respective tensile strength ratings and the at leastone tensile strength member having a tensile strength rating, the atleast one tensile strength member and one of the two strength componentsdefining a tensile strength ratio of about 0.1 to about 0.3.
 11. Thepreconnectorized outdoor cable of claim 1, the cable further comprisinga plurality of tensile strength members quadrilaterally disposed aboutthe optical transmission component.
 12. The preconnectorized outdoorcable of claim 1, the at least two strength components being disposed onopposite side of the optical transmission component.
 13. Thepreconnectorized outdoor cable of claim 1, one of the at least twostrength components being multifunctional so as to provide tensilestrength and waterblocking.
 14. The preconnectorized outdoor cable ofclaim 1, further comprising a heat shrink tube for weatherproofing thepreconnectorized outdoor cable, the heat shrink tube being disposedabout the second end of the shroud and a portion of the cable jacket.15. The preconnectorized outdoor cable of claim 1, further comprising anO-ring disposed on the shroud for weatherproofing the at least one plugconnector.
 16. The preconnectorized outdoor cable of claim 1, the shroudhaving at least one alignment indicia for indicating a matingorientation.
 17. The preconnectorized outdoor cable of claim 1, the atleast one plug connector having a protective cap and a retention wire,wherein the protective cap is attached to the at least one plugconnector by a retention wire.
 18. The preconnectorized outdoor cable ofclaim 1, a plurality of the components of the at least one plugconnector being formed from a UV stabilized material.
 19. Thepreconnectorized outdoor cable of claim 1, the cable having two plugconnectors.
 20. A preconnectorized outdoor cable, comprising: a cablecomprising: an optical transmission component; at least two strengthcomponents, the at least two strength components disposed on oppositesides of the optical transmission component; a plurality of tensilestrength members, the plurality of tensile strength members beinggenerally arranged about the optical transmission component andgenerally contacting the optical transmission component, the pluralityof tensile strength members being fibrous tensile strength members thatessentially lack anti-buckling strength; a toning portion, the toningportion including a conductive wire; and a cable jacket, the cablejacket contacting at least a portion of the optical transmissioncomponent; and at least one plug connector, the at least one plugconnector being attached to an end of the cable, thereby connectorizingan optical waveguide, the optical waveguide being a portion of theoptical transmission component.
 21. The preconnectorized outdoor cableof claim 20, one of the plurality of tensile strength members includinga water-swellable material.
 22. The preconnectorized outdoor cable ofclaim 20, one of the plurality of tensile strength members being aplurality fiberglass strands.
 23. The preconnectorized outdoor cable ofclaim 20, the two strength components being a dielectric material. 24.The preconnectorized outdoor cable of claim 20, the toning portion beinga toning lobe connected by a web, wherein the web can be torn toseparate the toning lobe.
 25. The preconnectorized outdoor cable ofclaim 20, the at least two strength components having respective tensilestrength ratings and the plurality of tensile strength member having atensile strength rating, one of the plurality of tensile strengthmembers and one of the two strength components defining a tensilestrength ratio of about 0.1 to about 0.3.
 26. The preconnectorizedoutdoor cable of claim 20, the plurality of tensile strength membersbeing quadrilaterally disposed about the optical transmission component.27. The preconnectorized outdoor cable of claim 20, one of the at leasttwo strength components being multifunctional so as to provide tensilestrength and waterblocking functions.
 28. The preconnectorized outdoorcable of claim 20, the at least one plug connector further comprising acrimp assembly and a connector assembly, wherein the crimp assemblyincludes a crimp housing and a crimp band and the connector assemblyincludes a connector housing and a ferrule, wherein the crimp housingcomprises two half-shells, the two half-shells having a longitudinalpassageway therethrough and at least one cable clamping portion, the atleast one cable clamping portion securing at least one strengthcomponent of the cable, and the two half-shells being held together bythe crimp band.
 29. The preconnectorized outdoor cable of claim 20, theat least one plug connector further comprising a crimp assembly and aconnector assembly, wherein the crimp assembly includes a crimp housingand a crimp band wherein the crimp housing comprises two half-shells,the two half-shells having a longitudinal passageway therethrough, atleast one cable clamping portion, and a connector assembly clampingportion, the at least one cable clamping portion securing at least onestrength component of the cable and the connector assembly clampingportion securing a portion of the connector assembly, and the twohalf-shells being held together by the crimp band.
 30. Thepreconnectorized outdoor cable of claim 20, the at least one plugconnector further comprising a shroud having a first end and a secondend, and a coupling nut.
 31. The preconnectorized outdoor cable of claim30, the shroud defining a pair of openings on opposite sides of thefirst end, the opening extending lengthwise from a medial portion of theshroud to the first end of the shroud, wherein the ferrule is accessiblewithin the first end of the shroud.
 32. The preconnectorized outdoorcable of claim 30, further comprising a heat shrink tube forweatherproofing the preconnectorized outdoor cable, the heat shrink tubebeing disposed about the second end of the shroud and a portion of thecable jacket.
 33. The preconnectorized outdoor cable of claim 30,further comprising an O-ring disposed on the shroud for weatherproofingthe at least one plug connector.
 34. The preconnectorized outdoor cableof claim 20, the at least one plug connector further comprising a shroudhaving a first end and a second end, wherein the shroud has at least onealignment indicia for indicating a mating orientation.
 35. Thepreconnectorized outdoor cable of claim 20, the at least one plugconnector further comprising a shroud having a first end and a secondend, the shroud has a plurality of fingers for mating with acomplementary receptacle, wherein at least two of the fingers havedifferent profiles for keying the plug connector with the complementaryreceptacle.
 36. The preconnectorized outdoor cable of claim 20, furthercomprising a heat shrink tube for weatherproofing the preconnectorizedoutdoor cable, the heat shrink tube being disposed over a portion of theat least one plug connector and a portion of the cable jacket.
 37. Thepreconnectorized outdoor cable of claim 20, the at least one plugconnector having a protective cap and a retention wire, wherein theprotective cap is attached to the at least one plug connector by aretention wire.
 38. The preconnectorized outdoor cable of claim 20, aplurality of the components of the at least one plug connector beingformed from a UV stabilized material.
 39. The preconnectorized outdoorcable of claim 20, further comprising two plug connectors.
 40. Thepreconnectorized outdoor cable of claim 20, the optical transmissioncomponent further comprising a dry insert.
 41. A preconnectorizedoutdoor cable, comprising: a cable including: an optical waveguide; atleast one tensile element; and a cable jacket; and at least one plugconnector, the at least one plug connector being attached to an end ofthe cable, thereby connectorizing an optical waveguide, the at least oneplug connector having a shroud with a first end and a second end, theshroud including a plurality of fingers for mating with a complementaryreceptacle, wherein at least two of the fingers have different profilesfor keying the plug connector with the complementary receptacle.
 42. Thepreconnectorized outdoor cable of claim 41, the at least one plugconnector further comprising a crimp assembly and a connector assembly,wherein the crimp assembly includes a crimp housing and a crimp bandwherein the crimp housing comprises two half-shells, the two half-shellshaving a longitudinal passageway therethrough, at least one cableclamping portion, and a connector assembly clamping portion, the atleast one cable clamping portion securing at least one strength memberof the cable and the connector assembly clamping portion securing aportion of the connector assembly, and the two half-shells being heldtogether by the crimp band.
 43. The preconnectorized outdoor cable ofclaim 41, the at least one plug connector further comprising a shroudhaving a first end and a second end, and a coupling nut.
 44. Thepreconnectorized outdoor cable of claim 43, the shroud defining a pairof openings on opposite sides of the first end, the opening extendinglengthwise from a medial portion of the shroud to the first end of theshroud, wherein the ferrule is accessible within the first end of theshroud.
 45. The preconnectorized outdoor cable of claim 43, furthercomprising a heat shrink tube for weatherproofing the preconnectorizedoutdoor cable, the heat shrink tube being disposed about the second endof the shroud and a portion of the cable jacket.
 46. Thepreconnectorized outdoor cable of claim 43, further comprising an O-ringdisposed on the shroud for weatherproofing the at least one plugconnector.
 47. The preconnectorized outdoor cable of claim 41, furthercomprising a heat shrink tube for weatherproofing the preconnectorizedoutdoor cable, the heat shrink tube being disposed over a portion of theat least one plug connector and a portion of the cable jacket.
 48. Thepreconnectorized outdoor cable of claim 41, the at least one plugconnector having a protective cap and a retention wire, wherein theprotective cap is attached to the at least one plug connector by aretention wire.
 49. The preconnectorized outdoor cable of claim 41, aplurality of the components of the at least one plug connector beingformed from a UV stabilized material.
 50. The preconnectorized outdoorcable of claim 41, further comprising two plug connectors.
 51. A fiberoptic cable comprising: an optical transmission component; at least twostrength components, the at least two strength components disposed onopposite sides of the optical transmission component; a plurality oftensile strength members, the plurality of tensile strength membersbeing generally arranged about the optical transmission component andgenerally contacting the optical transmission component, the pluralityof tensile strength members being fibrous tensile strength members thatessentially lack anti-buckling strength; a toning portion, the toningportion being a toning lobe that separable and includes a conductivewire; and a cable jacket, the cable jacket contacting at least a portionof the optical transmission component.
 52. The preconnectorized outdoorcable of claim 51, one of the plurality of tensile strength membersincluding a water-swellable material.
 53. The preconnectorized outdoorcable of claim 51, one of the plurality of tensile strength membersbeing a plurality fiberglass strands.
 54. The preconnectorized outdoorcable of claim 51, the two strength components being a dielectricmaterial.
 55. The preconnectorized outdoor cable of claim 51, the atleast two strength components having respective tensile strength ratingsand the at least one tensile strength member having a tensile strengthrating, one of the at least one tensile strength members and one of thetwo strength components defining a tensile strength ratio of about 0.1to about 0.3.
 56. The preconnectorized outdoor cable of claim 51, theplurality of tensile strength members being quadrilaterally disposedabout the optical transmission component.
 57. The preconnectorizedoutdoor cable of claim 51, one of the at least two strength componentsbeing multifunctional so as to provide tensile strength andwaterblocking.